Fitting new brake lines and front brakes

The later models Volvo 122S had a dual brake line system. Two brake lines to each brake for increased safety. They also had a brake booster and most RHD cars had a special construction to fit and operate this booster.

Brake booster  construction RHD Volvo 122S 1969

Brake booster Ate RHD Volvo 122S 1969

Dual brake line system Volvo 122S 1969

Replacing the front brake calipers is an easy job (if the bolts aren't too rusty..). The old ones were totally gone and it was cheaper to buy some reconditioned ones then buy all the parts and do it myself.

Old brake caliper - dual brake line system

Old brake caliper Volvo 122S

Reconditioned Girling brake caliper Volvo 122S

 The old brake pads looked OK so I decided to re-use them in the new calipers. If you want to change your brake pads, just remove the clips and the two retaining pins (don't forget the remove the split pins at the outer end of the retaining pins). If there's not enough room to fit the new brake pads (they are thicker then the old ones..) put back in the old ones, put a screwdriver between the pad and the brake disk and push/lever against the pad (sharp end of the screwdriver against the pad please!!) This way you'll push the pistons back into the caliper so there's more space for the new brake pads.

Reconditioned brake calipers with brake pads fitted

The only brake lines my Volvo 122S came with were the lines from the 6 way union in the engine bay to the rear brakes and the ones from the front calipers to the flexible brake hoses. No brake lines to the front brakes. Luckily you can buy complete brake line sets especially for the 122S. The only thing is you have to bent them...
That was a fiddly jobs, especially when you don't know where they supposed to go and you don't have the old ones as an example.
I got some nice pics and tips from other Volvo fans so I had something to work with.
Although you can bend the copper brake lines by hand, to get really nice curves it's better to use a special pipe bending plier.
When the brake lines are finally in place it's time to connect them with the union blocks or brake calipers. It's important to have a good fit without tension, otherwise they'll leak. Tighten the connection nut by hand and then give it an extra 1/8 -1/4 turn. That should by enough, Don't over tighten (= damage) the connections !

Fitting new brake lines Volvo Amazon 1969

New brake lines mounted on front axle Volvo 122S

New brake lines and - hoses front brakes

Brake lines from caliper to flexible brake hoses

I don't know if the brake booster is still OK but you can only test it when you drive the car. For now I cleaned it and gave it a fresh coat of paint and mounted a new master cylinder (not yet on the pic). 

Painted brake booster Ate - Volvo 122S

Before I put back the brake booster I want to fit the engine back into the engine bay...